The Mitsubishi Delica van has built a reputation for being rugged, versatile, and capable—making it a favorite among vanlife enthusiasts and off-road explorers. However, even the most reliable engines eventually wear out. Whether due to high mileage, overheating, or mechanical failure, replacing the engine in a Mitsubishi Delica can restore performance and keep your adventure vehicle on the road. This guide breaks down the process step by step. At Power Engines, we provide road-legal replacement engines built to OEM standards, making the process smoother and more reliable.
Preparation and Tools Required
Before starting, gather the right tools and workspace. You’ll need an engine hoist, jack stands, hydraulic jack, complete metric socket and wrench set, torque wrench, screwdrivers, pliers, drain pans, and protective gloves. Replacement fluids such as coolant, engine oil, and transmission fluid are also essential. Ensure the Delica is parked on a flat surface and disconnect the battery before beginning.
Step 1: Remove the Front Assembly and Drain Fluids
The Delica’s engine bay is compact, so removing the front grille, bumper, radiator, and fan assembly gives better access. Drain all fluids, including engine oil and coolant, into appropriate containers. This prevents spills and ensures a cleaner installation later.
Step 2: Disconnect Wiring, Hoses, and Fuel Lines
Label all wiring harnesses, vacuum hoses, and connectors before disconnecting them. Release pressure from the fuel system and carefully disconnect the fuel lines. Documenting connections with photos helps during reassembly.
Step 3: Remove Accessories and Exhaust Components
Unbolt the alternator, starter motor, and A/C compressor. To save time, secure the A/C and power steering components to the side without disconnecting fluid lines. Detach the exhaust manifold from the engine to free it for removal.
Step 4: Separate Transmission and Engine
Support the transmission with a jack or stand. Remove bolts connecting the engine to the transmission housing. If working on a manual Delica, disconnect the clutch linkage. For automatic models, remove the torque converter bolts before separating.
Step 5: Unbolt Motor Mounts and Extract the Engine
Remove the bolts securing the motor mounts. Attach the engine to the hoist using proper lifting points and carefully lift it out of the bay. Double-check that all hoses, wires, and lines are free before extraction.
Step 6: Prepare the Replacement Engine
Transfer necessary components from the old engine to the new one, such as intake and exhaust manifolds, sensors, and brackets. Replace worn gaskets, belts, and seals at this stage for long-term reliability. At Power Engines, our replacement engines for Mitsubishi Delica vans are built to meet or exceed OEM specifications, ensuring perfect fitment and emissions compliance.
Step 7: Install the New Engine
Lower the replacement engine into the bay, aligning it with the transmission and motor mounts. Tighten bolts to the proper torque specifications. Reconnect the exhaust system, transmission, and accessory components.
Step 8: Reconnect Wiring, Fuel, and Cooling Systems
Reattach all labeled wiring harnesses, fuel lines, and vacuum hoses. Install the radiator, cooling fan, and hoses. Refill the system with fresh fluids, including engine oil and coolant.
Step 9: Test the Engine and Perform Break-In
Reconnect the battery and switch the ignition to ON, allowing the fuel pump to prime the system. Start the engine and let it idle while checking for leaks, warning lights, or unusual noises. For the first 500 miles, avoid high RPMs and aggressive driving. Change the oil after this break-in period for maximum longevity.
Replacing the engine in a Mitsubishi Delica van may seem like a major undertaking, but with the right tools, preparation, and a step-by-step approach, it can be a highly rewarding project. The key to success is using a dependable replacement engine. At Power Engines, we provide road-legal, emissions-compliant engines designed to restore your Delica’s performance and reliability. Whether you’re preparing your van for daily use or long off-road expeditions, Power Engines has the solutions to keep your journey moving forward.
